1. 1. WORKSHOP MANUAL US VERSIONRIGHT HAND MODEL EXP UBSPubNo. RV99_02-01.E
2. 2. TOPWORKSHOP MANUAL 1998/1999 UBS2000 UBS2002 UBS
3. 3. HOME PAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No. CONTRNTS0A General Information0B Maintenance and Lubrication
4. 4. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS00 SERVICE INFORMATION1A HEATING AND VENTILATION1B AIR CONDITIONING1D COMPRESSOR OVERHAUL
5. 5. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS00 SERVICE INFORMATION2A FRONT END ALIGNMENT
6. 6. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS3C FRONT SUSPENSION3D REAR SUSPENSION; COIL SPRING3E WHEELS AND TIRES
7. 7. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No. CONTRNTS4A1DIFFERENTIAL (FRONT) 4A2ADIFFERENTIAL (Rear 220mm) 4A2BDIFFERENTIAL (REAR 244mm)4B1DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)4B2DRIVELINE CONTROL SYSTEM (TOD)4C DRIVE SHAFT SYSTEM4D1TRANSFER CASE (STANDARD TYPE)4D2TRANSFER CASE (TOD)
8. 8. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS5A BRAKE CONTROL SYSTEM5B ANTI-LOCK BRAKE SYSTEM5C POWER ASSISTED BRAKE SYSTEM5D PARKING BRAKES
9. 9. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS: 6VD1 / 6VE1SECTION No.CONTRNTS6A ENGINE MECHANICAL6B ENGINE COOLING6C ENGINE FUEL6D1ENGINE ELECTRICAL6D2IGNITION SYSTEM6D3STARTING AND CHARGING SYSTEM6E ENGINE DRIVEABILITY AND EMISSIONS6F ENGINE EXHAUST6G ENGINE LUBRICATION6H ENGINE SPEED CONTROL SYSTEM6J INDUCTION
10. 10. HOMEPAGE BACK PAGE NEXT4JG2SECTION No. CONTRNTS00SERVICE INFORMATION6AENGINE MECHANICAL6A2 4JG2-NA / 4JG2-TURBO ENGINE6BENGINE COOLING6CFUEL SYSTEM6DENGINE ELECTRICAL6E -6FEXHAUST6G - 4JX1SECTION No. CONTRNTS6AENGINE MECHANICAL6BENGINE COOLING6CENGINE FUEL6DENGINE ELECTRICAL6EENGINE DRIVEABILITY AND EMISSIONS6FENGINE EXHAUST6GENGINE LUBRICATION6HENGINE SPEED CONTROL6JINDUCTION
11. 11. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS7AAUTOMATIC TRANSMISSION (4L30-E)7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)7BMANUAL TRANSMISSION (AR-5)7BMANUAL TRANSMISSION (MUA)7CCLUTCH
12. 12. HOMEPAGE BACK PAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No. CONTRNTS8A LIGHTING SYSTEM8B WIPER / WASHER SYSTEM8C ENTERTAINMENT8D WIRING SYSTEM8E METER AND GAUGE8F BODY STRUCTURE8G SEATS8H SECURITY AND LOCKS8I SUN ROOF/CONVERTIBLE TOP8J EXTERIOR / INTERIOR TRIM
13. 13. HOMEPAGE BACK PAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS9A SEAT BELT SYSTEM9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS)9J1RESTRAINT CONTROL SYSTEM
14. 14. HOMEPAGE BACKTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS10ACRUISE CONTROL SYSTEM
15. 15. SECTION GENERAL INFORMATION 0A1SECTION 0A GENERAL INFORMATION CONTENTS PAGEGeneral Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A 2How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A 3Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A 6Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A 8Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A10Recommended Liquid Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A11Recommended Thread Locking Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A11Abbreviations Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A12Service PrecautionCAUTION: Always use the correct fastener in theproper location. When you replace a fastener, useWARNING: THIS VEHICLE HAS A SUPPLEMENTALONLY the exact part number for that application.RESTRAINT SYSTEM (SRS). REFER TO THE SRSISUZU will call out those fasteners that require aCOMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call outORDER TO DETERMINE WHETHER YOU AREthe fasteners that require thread lockers or threadPERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do notCOMPONENTS OR THE SRS WIRING. WHEN YOUuse supplemental coatings (Paints, greases, orARE PERFORMING SERVICE ON OR NEAR THE other corrosion inhibitors) on threaded fastenersSRS COMPONENTS OR THE SRS WIRING, REFER or fasteners joint interfaces. Generally, suchTO THE SRS SERVICE INFORMATION. FAILURE coatings adversely affect the fastener torque andTO FOLLOW WARNINGS COULD RESULT INthe joint clamping force, and may damage thePOSSIBLE AIR BAG DEPLOYMENT, PERSONAL fastener. When you install fasteners, use theINJURY, OR OTHERWISE UNNEEDED SRS correct tightening sequence and specification.SYSTEM REPAIRS. Following these instructions can help you avoiddamage to parts and systems.
16. 16. 0A2 GENERAL INFORMATIONGENERAL REPAIR INSTRUCTIONS 1. Park the vehicle on level ground and chock the11. Keep fixing nuts and bolts separate.front or rear wheels before lifting the vehicle.Fixing nuts and bolts vary in hardness and 2. Use covers on the vehicle body, seats, anddesign according to installation positions.floor to prevent damage and/or12. Clean all parts before inspection orcontaminations. reassembly. 3. Disconnect the grounding cable from the 13. Clean the oil ports and other openings withbattery before performing service operations. compressed air to make certain that they areThis will prevent cable damage or burning due free of dirt and obstructions.to shortcircuiting. 14. Lubricate the rotating and sliding faces of all 4. Raise the vehicle with a jack set against the moving parts with oil or grease beforerecommended lifting points (see Liftinginstallation.instructions in this section). 15. Use the recommended liquid gasket to prevent 5. Support the vehicle on chassis stands.leakage. 6. Handle brake fluid and antifreeze solution with 16. Carefully observe all nut and bolt torquegreat care. specifications.Spilling these liquids on painted surfaces will 17. When service operation is completed, make adamage the paint. final check to be sure service has been done 7. The use of the proper tool(s) and special tool(s) properly and problem has been corrected.where specified is essential to efficient,18. When removing or replacing parts that requirereliable, and safe service operations.refrigerant to be discharged from the air 8. Always use genuine ISUZU replacement parts. conditioning system, be sure to use the 9. Discard used cotter pins, gasket, plastic clips,following tools to recover and recycle theO-rings, oil seals, lock washers, and self- Refrigerant-134a (R-134a).locking nuts at disassembly.For 134a:Normal function of these parts cannot beUse the R-134a Refrigerant Recovery/Recovery/guaranteed if they are reused.Recycling/Recharging/System (ACR4) or its10. Keep the disassembled parts neatly in groups. equivalent to prevent the discharge ofThis will facilitate smooth and correct refrigerant into the air.reassembly.
17. 17. GENERAL INFORMATION 0A3HOW TO USE THIS MANUAL 1. Find the applicable section by referring to the 4. The service operations are in two groups: one istable of contents on the introduction page ofthe On-vehicle service where operations caneach manual. be directly performed on the vehicle, and the2. In Service Information, an opening section of other is the Unit repair where the operationseach manual, the troubleshooting, maintenanceare done on the work bench after removing theservicing, service data and/or information onunit from the vehicle.special tools required for the service operations 5. Each service operation section begins with adescribed in the next subsequent sections aredisassembled view of unit or equipment, whicharranged and compiled so concisely that youis useful to find relative components, servicecan see at a first glance. procedure, availability and contents of repair 3. Each section except the Service Informationkits, etc.section is basically arranged in the followingorder of headings: General description On-vehicle service Unit repairThe number represents sequence ofremoval or disassemblyRemoval of unnumbered the parts(excluding bolts, nuts, washers,gaskets, cotter pins, etc.) isunnecessary unless replacement isneeded.Where parts replacement requiresspecific information, instructions aregiven in Inspection and Repair.This frame is to be removed as alarge disassembly with all the partsassembled in the frame. Each one ofthe parts in the frame is removed asa small disassembly.Parts to be removed or installed as aunit.5 Parts contained in repair kit.5 Indicates repair kit availability.When the installation (reassembly)procedure is the reverse order of theremoval (disassembly) procedure,the sequence of service operationand the parts names will be omitted.Name of parts listed in sequence ofservice operation.
18. 18. 0A4 GENERAL INFORMATION For illustrations where there are few items to be performed:The sequence of removal(disassembly) and the parts nameswill be given.6. After the illustration, the details of each information such as the notes in each operation, operation are shown in the order the operations and places where special tools are to be used are carried out in the illustration. Refer to the and their usage, and the specified service data. explanations when checking important The symbol mark attached to the title indicates the action to be taken in the operations of each title. Example for this case;1st step Reassemble pinion shaft The numbers given to the installation (assembly) procedure are the same as those given in the removal (disassembly) procedure in the illustration. Therefore, start with the larger number during reassembly. The titles of operations done in the illustration are given in bold letters. They are described in the order of the procedure of the operations. Special tools are identified with tool name and/or tool number. The drawing illustrates how the tool is used. Service data and specifications are listed in table. Important note. The action symbol indicates the step of service to be followed. Refer to the following paragraph for the meaning of each symbol.
19. 19. GENERAL INFORMATION 0A57. In this manual, the following action symbols are used to indicate the type of service operations to be performed. ... Remove or disconnect ...Adjust ... Install or connect ...Clean ... Disassemble...Pay close attention - Important ... Reassemble ...Tighten to specified torque ... Align the marks...Use special tool(s) ... Correct direction...Lubricate with oil ... Inspect...Lubricate with grease ... Take measurement ...Use liquid gasket8. The service standard is indicated in terms of considered serviceable. Standard and Limit. Limit indicates the limit value (Correction or The Standard means the assembly standardreplacement is necessary when measurement and standard range within which the parts are is beyond this limit.)
20. 20. 0A6 GENERAL INFORMATIONIDENTIFICATIONVEHICLE IDENTIFICATION NUMBER (VIN) ISUZU MOTORS LTD. VINThis is the legal identification of the vehicle.It appears on the manufacturers Plate attached to the leftof the engine compartment front end. VIN number is alsostamped on the rear right side of the frame. VIN JAC UBS 26G Y 7 200001Sequential NumberPlant CodeModel Year (Y: 2000)Wheel Base (D: Short, G: Long)Engine Type (26: 6VE1, 73: 4JX1)Vehicle ModelWorld Manufacturer IdentifierENGINE SERIAL NUMBERThe engine serial number is stamped on the left rear lowerarea of the cylinder block above the starter. 4JX1 905RW014 6VE1 905RW016
21. 21. GENERAL INFORMATION 0A7 TRANSMISSION SERIAL NUMBER Manual: Stamped on the left side of the transmission intermediate plate.905RW015 Automatic: Stamped on the identification plate, located onthe left side of the transmission above themode switch. HYDRAMATIC FP PART No. STRASBOURG MADE IN FRANCE96 018 272 SALSERIAL No.G 20 0000 000905RW018Service parts ID plate SERVICE PARTS IDENTIFICATION PLATE ISUZU MOTORS L T D. JAPAN V.I.N. The Vehicle Information Plate (Service Parts ID plate) is M.D. ENGINE GRADE BODY TYPE TRANS. TIREprovided on all vehicle models. B. COLOR/TRIM OPTION It is located on the center dash wall inside the engine compartment. The plate lists the VIN (Vehicle Identification Number), paint information and all production options and special equipment on the vehicle when it was shipped from the factory.905RW007
22. 22. 0A8 GENERAL INFORMATION LIFTING INSTRUCTIONS CAUTION: When jacking or lifting a vehicle at the If a lifting device other than the original jack frame side rail or other prescribed lift is used, it is most important that the devicepoints, be certain that lift pads do not be applied only to the correct lifting points. contact the catalytic converter, brake Raising the vehicle from any other point pipes or cables, or fuel lines. Such contact may result in serious damage.may result in damage or unsatisfactoryvehicle performance.LIFTING POINTS AND SUPPORTABLE POINT LOCATIONSLong wheel Base ModelShort Wheel Base ModelLifting pointSupportable point
23. 23. GENERAL INFORMATION 0A9LIFTING POINT; FRONTWhen using floor jack, lift on the center of the skid plate.SUPPORTABLE POINT; FRONTPosition the chassis stands at the bottom of the framesidemember, backward of front wheel.LIFTING POINT; REARPosition the floor jack at the center of the rear axle casewhen lifting the vehicle.SUPPORTABLE POINT; REARPosition the chassis stands at the bottom of the framesidemember, just behind of the trailing link bracket.SUPPORTABLE POINT; REARPosition the chassis stands at the bottom of the rear axlecase.
24. 24. 0A10 GENERAL INFORMATION TORQUE SPECIFICATIONSSTANDARD BOLTSThe torque values given in the following table should be applied where a particular torque is not specified.Nm (kgm / lbft)Nm kgcm / lbinStrength 4.8 8.8 9.8 Class RefinedNon-Refined Bolt Identifi- cation 4 8 89BoltDiameter x No markPitch (mm) M 6x1.06 (60 / 527 (75 / 65 M 8x1.2513 (130 / 11317 (175 / 152 24 (240 / 208 M10x1.2527 (2.8 / 20)37 (3.8 / 27) 50 (5.1 / 37) M12x1.2561 (6.3 / 45)76 (7.8 / 56) 95 (9.7 / 70) M14x1.5 96 (9.8 / 71) 116 (11.9 / 86)142 (14.5 / 105) M16x1.5130 (13.3 / 96)170 (17.3 / 125) 200 (20.4 / 148) M18x1.5188 (19.2 / 139) 244 (24.9 / 180) 287 (29.3 / 212) M20x1.5258 (26.3 / 190) 337 (34.4 / 249) 396 (40.4 / 292) M22x1.5332 (33.9 / 245) 453 (46.3 / 335) 530 (54.1 / 391) M24x2.0449 (45.8 / 331) 570 (58.2 / 421) 692 (70.6 / 511)*M10x1.5 26 (2.7 / 20)36 (3.7 / 27) 48 (4.9 / 35)*M12x1.5 57 (5.8 / 42)71 (7.2 / 52) 89 (9.1 / 66)*M14x2.0 89 (9.1 / 66) 110 (11.2 / 81)133 (13.6 / 98)*M16x2.0124 (12.7 / 92)162 (16.5 / 119) 191 (19.5 / 141)The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materialssuch as casting, etc. FLARE NUTS Nm (kgm / lbft)Pipe diameter mm (in)TorquePipe diameter mm (in) Torque4.76 (0.187)16 (1.6 / 12)10.00 (0.394) 54 (5.5 / 40)6.35 (0.250)26 (2.7 / 20)12.00 (0.472) 88 (9.0 / 65)8.00 (0.315)44 (4.5 / 33)15.00 (0.591) 106 (10.8 / 78)
25. 25. GENERAL INFORMATION 0A11 RECOMMENDED LIQUID GASKET TypeBrand Name ManufacturerRemarks RTV* Three Bond 1207BThree BondFor Engine RepairsSilicon BaseThree Bond 1207CThree BondThree Bond 1215 Three BondFor Axle CaseThree Bond 1280 Three BondRepairs. T/M Water Base Three Bond 1141EThree BondFor Engine RepairsThree Bond 1104 Three BondBelco Bond 4Isuzu SolventFor Engine RepairsBelco Bond 401IsuzuBelco Bond 402IsuzuLOCTITE 515 Loctite AnaerobicAllLOCTITE 518 Loctite* RTV: Room Temperature VulcanizerNOTE:1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.2. Be careful to use the specified amount of liquid gasket. Follow the manufacturers instructions at all times.3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applyingthe liquid gasket. The connecting surfaces must be perfectly dry.4. Do not apply LOCTITE 515 and LOCTITE 518 between two metal surfaces having a clearance of greaterthan 0.25 mm (0.01 in). Poor adhesion will result.RECOMMENDED THREAD LOCKING AGENTS LOCTITE Type LOCTITE Color Application Steps1. Completely remove all lubricant and moisture from the boltsLOCTITE 242Blueand the female threaded surfaces of the parts to be joined. The surfaces must be perfectly dry.2. Apply LOCTITE to the bolts.LOCTITE 262 RedApply LOCTITE to at least 1/3 of the bolts threaded areaLOCTITE 270 Green3. Tighten the bolts to the specified torque.LOCTITE 271 RedAfter tightening, be sure to keep the bolts free from vibration and torque for at least an hour until LOCTITE hardens.NOTE: When the application procedures are specified in this manual, follow them.
26. 26. 0A12 GENERAL INFORMATIONABBREVIATIONS CHARTS LIST OF AUTOMOTIVE ABBREVIATIONS WHICH MAY BE USED IN THIS MANUALA Ampere(s)EAC Electric Air ControlABS Antilock Brake SystemEAS Electric Air SwitchingA/C Air Conditioning EBCM Electronic Brake Control ModuleACCEL AcceleratorECC Electronic Climate ControlACC AccessaryECM Electronic Control ModuleAdj Adjust ECU Electronic Control UnitA/F Air Fuel Ratio Engine Calibration Unit (PROM)AIR Air Injection Reaction SystemEECS Evaporative Emission Control SystemALDL Assembly Line Diagnostic Link EFE Early Fuel EvaporationAlt Altitude EFI Electronic Fuel InjectionAMP Ampere(s)EGR Exhaust Gas RecirculationANT AntennaEGR/TVS Exhaust Gas Recirculation/ThermostaticAPS Absolute Pressure SensorVacuum SwitchASM Assembly ELC Electronic Level ControlA/T Automatic Transmission/Transaxle ESC Electronic Spark ControlATDC After Top Dead Center EST Electronic Spark ControlAuth Authority ETR Electronically Tuned ReceiverAuto Automatic EVRV Electronic Vacuum Regulator Valve (EGR)BARO Barometic Exh ExhaustBat BatteryF Degrees FahrenheitBat+ Battery Positive Terminal FF Front Drive Front EngineBbl Barrel FL Fusible LinkBCM Body Control ModuleFLW Fusible Link WireBHP Brake Horsepower FRT FrontBP Back Pressure FWD Front Wheel DriveBTDC Before Top Dead Center4WD Four Wheel DriveC Degrees Celsius4x4 Four Wheel DriveCat. Conv. Catalytic Converter 4 A/T Four Speed Automatic Transmission/Transaxlecc Cubic CentimeterGal GallonCCC Computer Command Control Gen GeneratorCCOT Cycling Clutch Orifice Tube Gov GovernorCCP Controlled Canister Purgeg GramCID Cubic Inch DisplacementHarn HarnessCL Closed Loop HC HydrocarbonsCLCC Closed Loop Carburetor ControlHD Heavy DutyCO Carbon Monoxide HEI High Energy IgnitionCoax Coaxial Hg MercuryConn Connector HiAlt High AltitudeConv Converter HVAC Heater-Vent-Air ConditioningCP Canister Purge IAC Idle Air ControlCPS Central Power Supply IC Integrated CircuitCrank Crankshaft ID IdentificationCTS Coolant Temperature Sensor Inside DiameterCu.In. Cubic InchIDI Integrated Direct IgnitionCV Constant Velocity IGN IgnitionCyl Cylinder(s)ILC Idle Load CompensatorC3I Computer Controlled Coil IgnitionINJ InjectionDBM Dual Bed MonolithIP Instrument PanelDiff DifferentialIPC Instrument Panel ClusterDIS Direct Ignition System INT IntakeDist DistributorJ/B Junction BlockDOHC Double Overhead Camshaftkm KilometersDVM Digital Voltmeter (10 meg.)km/h Kilometer per HourDVOM Digital Volt Ohmmeter kPa KiloPascalsDVDV Differential Vacuum Delay Valve KV Kilovolts (thousands of volts) KW Kilowatts
27. 27. GENERAL INFORMATION 0A13L Liter SAE Society of Automotive Engineerslbft Foot Pounds Sec Secondarylbin Inch Pounds SFI Sequential-port Fuel InjectionLF Left Front SI System InternationalLH Left HandSIR Supplemental Inflatable Restraint SystemLR Left RearSOHC Single Overhead CamshaftLS Left SideSol SolenoidLWB Long Wheel Base SPEC SpecificationL-4 In-line Four Cylinder EngineSpeedo SpeedometerMAF Mass Air Flow SRS Supplemental Restraint SystemMAN ManualST StartMAP Manifold Absolute PressureSw SwitchMAT Manifold Air TemperatureSWB Short Wheel BaseMEM-CAL Memory and Calibration Unit SYN SynchronizeMax Maximum TAC Thermostatic Air CleanerM/C Mixture Control Tach TachometerMin Minimum TBI Throttle Body Injectionmm Millimeter TCC Transmission/Transaxle Converter ClutchMPFI Multi-Port Fuel InjectionTCM Transmission/Transaxle Control ModuleMPG Miles per GallonTDC Top Dead CenterMPH Miles per HourTerm TerminalM/T Manual Transmission/Transaxle TEMP TemperatureMV MillivoltTPS Throttle Position SensorNA Natural AspiratedTRANS Transmission/TransaxleNC Normally ClosedTURBO TurbochargerNm Newton Meters TV Throttle ValveNO Normally OpenTVRS Television & Radio SuppressionNOx Nitrogen, Oxides of TVS Thermal Vacuum SwitchOD Outside Diameter 3 A/T Three Speed Automatic Transmission/O/D Over Drive TransaxleOHC Overhead Camshaft 2WD Two Wheel DriveOL Open Loop4x2 Two wheel DriveO2 Oxygen U-joint Universal JointPAIR Pulse Air Injection Reactor System V Volt(s)P/B Power BrakesVAC VacuumPCV Positive Crankcase VentilationVIN Vehicle Identification NumberPFI Port Fuel Injection VRRRE Vehicle Refrigerant Recovery and RecyclingPRESS PressureEquipmentPROM Programmable Read Only MemoryV-ref ECM Reference VoltageP/N Park/NeutralVRV Vacuum Reducer ValveP/S Power SteeringVSS Vehicle Speed SensorPSI Pounds per Square InchVSV Vacuum Switching ValvePt. PintV-6 Six Cylinder V EnginePri Primary V-8 Eight Cylinder V EnginePWM Pulse Width Modulated W Watt(s)Qt Quartw/ WithREF Reference w/b Wheel BaseRF Right Frontw/o WithoutRFI Radio Frequency InterferenceWOT Wide Open ThrottleRH Right HandRPM Revolutions per MinuteRPO Regular Production OptionRR Right RearRS Right SideRTV Room Temperature VulcanizingRVB Rear Vacuum BrakeRVR Response Vacuum ReducerRWAL Rear Wheel Antilock BrakeRWD - Rear Wheel Drive
28. 28. SECTIONMAINTENANCE AND LUBRICATION 0B1SECTION 0B MAINTENANCE AND LUBRICATION CONTENTSPAGEMaintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B 2Recommended Fluids, Lubricants and Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B 7Oil Viscosity Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B10Service PrecautionCAUTION: Always use the correct fastener in theproper location. When you replace a fastener, useWARNING: THIS VEHICLE HAS A SUPPLEMENTALONLY the exact part number for that application.RESTRAINT SYSTEM (SRS). REFER TO THE SRSISUZU will call out those fasteners that require aCOMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call outORDER TO DETERMINE WHETHER YOU AREthe fasteners that require thread lockers or threadPERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do notCOMPONENTS OR THE SRS WIRING. WHEN YOUuse supplemental coatings (Paints, greases, orARE PERFORMING SERVICE ON OR NEAR THE other corrosion inhibitors) on threaded fastenersSRS COMPONENTS OR THE SRS WIRING, REFER or fasteners joint interfaces. Generally, suchTO THE SRS SERVICE INFORMATION. FAILURE coatings adversely affect the fastener torque andTO FOLLOW WARNINGS COULD RESULT INthe joint clamping force, and may damage thePOSSIBLE AIR BAG DEPLOYMENT, PERSONAL fastener. When you install fasteners, use theINJURY, OR OTHERWISE UNNEEDED SRS correct tightening sequence and specification.SYSTEM REPAIRS. Following these instructions can help you avoiddamage to parts and systems.
29. 29. 0B2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULEGASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: AdjustR: Replace or change T: Tighten to specified torque L: LubricateSERVICE INTERVAL:x 1,000 km5 10 15 20 25 30 3540 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer readingx 1,000 miles 369 12 15 18 2124 27 30 33 36 39 42 45 48 51 54 57 60or months whichever comes first) or months 6 12 18 24 30 36 4248 54 60 66 72 78 84 90 96 102 108 114 120GASOLINE ENGINE* Engine oil - -R --R -- R --R-- R- - R - -* Engine oil filter- -R --R -- R --R-- R- - R - - Oil leakage and contamination - -R --I -- I -- I -- I- - I - -* Timing belt(Replace every 165,000 km or 100,000 miles) Spark plugs (For leaded fuel use) - -- --- - R- -- - -- -R - - - - Spark plugs (Forunleaded fuel use)(Replace every 165,000 km or 100,000 miles) Exhaust system- -I --I -- I -- I -- I- - I - - Radiator coolant concentration- -I --I -- I -- I -- I- - I - - Cooling system for water leakage- -I --I -- I -- I -- I- - I - - All hoses and pipes in engine compartment for clog or damage- -I--I - - I --I - - I- -I- - Fuel filter - ---- R- - - -- R- - -- - R - - Fuel leakage- -I--I - - I --I - - I- -I- - Fuel tank - -I--I - - I --I - - I- -I- -* Air cleaner element- -I--I - - R --I - - I- - R - - Pre air cleaner - -I--I - - I --I - - I- -I- - Engine drive belt - ----I - - - --I - - -- -I- - Valve clearance (Check and adjust if necessary every 100,000 km or 60,000 miles) O2 Sensor (For leaded fuel use) - ----- - - - R- -- - -- --- R O2 Sensor (For unleaded fuel use)(Replace every 150,000 km or 90,000 miles)CLUTCHClutch fluid - -I - -I- -I - -I--I- - I - -Clutch pedal travel and free play- -I - -I- -I - -I--I- - I - -TRANSMISSION OR TRANSMISSION WITHTRANSFER CASE* Manual transmission with transfer case oil - -R - -I- -R - -I--R- - I - I* AT Automatic transmission fluid leakage- -I - -I- -I - -I--I- - I - -*(1) AT Automatic transmission fluid - -- - --- -- - ------ - - - I* AT Transfer case oil - -R - -I- -R - -I--R- - I - IPROPELLER SHAFTLoose connections- -I - -I- -I - -I--I- - I - -* Universal joints and splines for wear- -I - -I- -I - -I--I- - I - -Universal joints and sliding sleeve (front and rear) - -L - -L- -L - -L--L- - L - -FRONT AND REAR AXLE* Differential gear oil (Front and rear) - -R - -I- -R - -I--R- - I - IShift on the fly system gear oil - -I - -I- -I - -I--I- - I - -Front axle shaft rubber boot for damage- -I - -I- -I - -I--I- - I - -Axle case for distortion or damage - -I - -I- -I - -I--I- - I - -Axle shafts for distortion or damage - -I - -I- -I - -I--I- - I - -STEERING* Power steering fluid - -I - -I- -R - -I--I- - R - - Oil leakage - -I - -I- -I - -I--I- - I - -* Steering system for looseness or damage- -I - -I- -I - -I--I- - I - - Power steering hose - -I - -I- -I - -I--R- - I - - Steering wheel play - -I - -I- -I - -I--I- - I - - Steering function - -I - -I- -I - -I--I- - I - - Right and left turning radius - -- - -I- -- - -I---- - I - - Wheel alignment - -- - -I- -- - -I---- - I - - Joint ball for oil leakage or damage- -I - -I- -I - -I--I- - I - - Joint ball rubber boot for damage - -I - -I- -I - -I--I- - I - -SERVICE BRAKES Brake fluid - -I - -I- -R - -I--I- - R - - Brake system for fluid leakage- -I - -I- -I - -I--I- - I - - Brake function- -I - -I- -I - -I--I- - I - -* Disc brake pads and discs wear - -I - -I- -I - -I--I- - I - - Brake pedal travel and free play- -I - -I- -I - -I--I- - I - - Pipes and hoses for loose connections or damage - -I - -I- -I - -I--I- - I - -(1): Adjust or change automatic transmission fluid.*Marks:Under severe driving conditions, additional maintenance is required. Refer to Maintenance schedule under severe driving conditions.
30. 30. MAINTENANCE AND LUBRICATION 0B3GASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: AdjustR: Replace or change T: Tighten to specified torqueL: LubricateSERVICE INTERVAL:x 1,000 km510 15 20 25 30 35 4045 50 55 6065 70 75 80 85 90 95 100(Use odometer readingx 1,000 miles 3 69 12 15 18 21 2427 30 33 3639 42 45 48 51 54 57 60or months whichever comes first) or months 612 18 24 30 36 42 4854 60 66 7278 84 90 96 102 108 114 120PARKING BRAKE Parking brake function - -I- - I--I --I --I- - I - - Parking brake lever travel - -I- - I--I --I --I- - I - - Cables for looseness or damage and guide for - -I- - I--I --I --I- - I - - damage Ratchet for wear or damage - -I- - I--I --I --I- - I - -SUSPENSION Spring leaves for damage - -I- - I--I --I --I- - I - - Mount for looseness or damage- -I- - I--I --I --I- - I - - Shock absorbers for oil leakage- -I- - I--I --I --I- - I - - Shock absorbers mount for looseness- -I- - I--I --I --I- - I - - Rubber bushes of suspension wear or damage - -I- - I--I --I --I- - I - - Spring action for loss of balance due to weakening - -I- - I--I --I --I- - I - - Joint ball rubber boot for damage- -I- - I--I --I --I- - I - -WHEELS Wheel pins - -T- - T-- T - -T --T- - T - - Wheel disc for damage- -I- - I--I- -I --I- - I - - Hub bearinggrease- --- - R---- - R---- - R - - Front and rear hub bearings for looseness- -I- - I--I- -I --I- - I - - Tire pressure and damage - -I- - I--I- -I --I- - I - - Tire rotation(Rotate as required)OTHERS Bolts and nuts on chassis and body - -I- - I--I --I --I- - I - - Lube front free-wheeling hubs- --- - L--- --L ---- - L - - *Marks:Under severe driving conditions, additional maintenance is required.Refer to Maintenance schedule under severe driving conditions.
31. 31. 0B4 MAINTENANCE AND LUBRICATIONDIESEL ENGINE MODELI: Inspect and correct or replace as necessary A: AdjustR: Replace or change T: Tighten to specified torqueL: LubricateSERVICE INTERVAL:x 1,000 km5 10 15 2025 30 3540 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer readingx 1,000 miles 369 1215 18 2124 27 30 33 36 39 42 45 48 51 54 57 60or months whichever comes first) or m onths6 12 18 2430 36 4248 54 60 66 72 78 84 90 96 102 108 114 120DIESEL ENGINE* Engine oil - R-R- R- R- R - R- R-R - R - R* Engine oil filter- R-R- R- R- R - R- R-R - R - ROil leakage and contamination- I-I-I - I- I - I- I-I - I - IIdling speed and acceleration- I-I-I - I- I - I- I-I - I - IFan belt tension and damage- I-I-I - I- I - I- I-I - I - ITiming belt (Replace every 200,000 km or 125,000 miles)Exhaust system - I-I-I - I- I - I- I-I - I - IAll hoses and pipes in engine compartment- I-I-I - I- I - I- I-I - I - I for clog or damageValve clearance- --A- -- --A-----A - - - -* Air cleaner element- ---- -- --------R - - - -Fuel filter- ---- -- --------R - - - -Radiator coolant concentration - I-I- I- I-I-I-I-I - I - ICooling system for water leakage - I-I- I- I-I-I-I-I - I - ICLUTCHClutch fluid - I-I -I- I- I -I-I-I - I - IClutch pedal travel and free play- I-I -I- I- I -I-I-I - I - ITRANSMISSION OR TRANSMISSION WITHTRANSFER CASE* Manual transmission with transfer case oil - R-I --- R---I---R - - - I* AT Automatic transmission fluid- --I --- I---I---I - - - I* AT Transfer case oil - R-I --- R---I---R - - - IPROPELLER SHAFTLoose connections- I-I -I- I-I-I-I-I - I - I* Universal joints and splines for wear- I-I -I- I-I-I-I-I - I - IUniversal joints and sliding sleeve (front and rear) - L-L -L- L-L-L-L-L - L - LFRONT AND REAR AXLE* Differential gear oil (Front and rear) - R-I --- R---I---R - - - IShift on the fly system gear oil - --I --- I---I---I - - - IFront axle shaft rubber boot for damage- --I --- I---I---I - - - IAxle case for distortion or damage - --I --- I---I---I - - - IAxle shafts for distortion or damage - --I --- I---I---I - - - ISTEERING* Power steering fluid - I-I -I- R-I-I-I-R - I - IOil leakage- I-I -I- I-I-I-I-I - I - I* Steering system for looseness or damage- I-I -I- I-I-I-I-I - I - IPower steering hose- I-I -I- I-I-I-R-I - I - ISteering wheel play- I-I -I- I-I-I-I-I - I - ISteering function- I-I -I- I-I-I-I-I - I - IRight and left turning radius- --I --- I---I---I - - - IWheel alignment- --I --- I---I---I - - - IJoint ball for oil leakage or damage - I-I -I- I-I-I-I-I - I - IJoint ball rubber boot for damage- I-I -I- I-I-I-I-I - I - ISERVICE BRAKESBrake fluid- --I --- R---I---R - - - IBrake system for fluid leakage - I-I -I- I-I-I-I-I - I - IBrake function - I-I -I- I-I-I-I-I - I - I* Disc brake pads and discs wear - I-I -I- I-I-I-I-I - I - IBrake pedal travel and free play - I-I -I- I-I-I-I-I - I - IPipes and hoses for loose connections or damage- I-I -I- I-I-I-I-I - I - INOTE: In the 4JXI-TC diesel engine, there is provided sub (2nd) oil filter for fuel injection at the upper part of crank case on the leftside of the engine. This oil filter maintenance-free and does not need a periodic replacement. See reverse side the (back)cover for installation location of the sub (2nd) oil filter. *Marks:Under severe driving conditions, additional maintenance is required.Refer to Maintenance schedule under severe driving conditions.
32. 32. MAINTENANCE AND LUBRICATION 0B5DIESEL ENGINE MODELI: Inspect and correct or replace as necessary A: AdjustR: Replace or change T: Tighten to specified torqueL: LubricateSERVICE INTERVAL:x 1,000 km510 15 20 25 30 35 4045 50 55 6065 70 75 80 85 90 95 100(Use odometer readingx 1,000 miles 3 69 12 15 18 21 2427 30 33 3639 42 45 48 51 54 57 60or months whichever comes first) or months 612 18 24 30 36 42 4854 60 66 7278 84 90 96 102 108 114 120PARKING BRAKE Parking brake function - --I - --I- --I ---I - - - I Parking brake lever travel - --I - --I- --I ---I - - - I Cables for looseness or damage and guide for - --I - --I- --I ---I - - - I damage Ratchet for wear or damage - --I - --I- --I ---I - - - ISUSPENSION Spring leaves for damage - I-I - I-I- I-I -I-I - I - I Mount for looseness or damage- I-I - I-I- I-I -I-I - I - I Shock absorbers for oil leakage- I-I - I-I- I-I -I-I - I - I Shock absorbers mount for looseness- I-I - I-I- I-I -I-I - I - I Rubber bushes of suspension wear or damage - I-I - I-I- I-I -I-I - I - I Spring action for loss of balance due to weakening - --I - --I- --I ---I - - - I Joint ball rubber boot for damage- I-I - I-I- I-I -I-I - I - IWHEELS Wheel pins - T-T - T-T- T - T -T-T - T - T Wheel disc for damage- I-I - I-I-I- I -I-I - I - I Hub bearing grease - --- - R----- R ---- - R - - Front and rear hub bearings for looseness- I-I - I-I-I- I -I-I - I - I Tire pressure and damage - I-I - I-I-I- I -I-I - I - I Tire rotation(Rotate as required)OTHERS Bolts and nuts on chassis and body - I-I - I-I- I-I -I-I - I - I Lube front free-wheeling hubs- --- - L--- --L ---- - L - - *Marks:Under severe driving conditions, additional maintenance is required.Refer to Maintenance schedule under severe driving conditions.
33. 33. 0B6 MAINTENANCE AND LUBRICATIONMAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONSSevere driving conditions A:Repeated short trips B:Driving on rough roads C:Driving on dusty roads D:Driving in extremely cold weather and/or salted roadsConditionItem IntervalA BC DA+D Engine oilG : Change every 5,000 km (3,000 miles) qq D : Change every 5,000 km (3,000 miles) Engine oil filter G : Replace every 10,000 km (6,000 miles) qq D : Replace every 5,000 km (3,000 miles) Air cleaner element G : Replace every 20,000 km (12,000 miles) q D : Replace every 40,000 km (25,000 miles) Power steering fluidReplace every 50,000 km (30,000 miles) qq Steering system for looseness Inspect every 5,000 km (3,000 miles) q or damage Universal joints and sleevesInspect for wear and lubricate every 7,500 km (4,500 miles)qq Transmission withMTChange every 20,000 km (12,000 miles)q transfer case oilafter changing at initial 10,000 km (6,000 miles)Transmission :ATq qqqChange every 32,000 km (20,000 miles)Transfer:TFChange every 20,000 km (12,000 miles) qafter changing at initial 10,000 km (6,000 miles) Differential oilChange every 20,000 km (12,000 miles) after changing at initial 5,000 km (3,000 miles) q Disc brake pads and discs Inspect every 5,000 km (3,000 miles) q qq Timing belt G : Replace every 120,000 km (75,000 miles) qqEXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULEExplanations of the services listed in the proceedingReplace all questionable parts and note anyMaintenance Scheduled are presented in Servicenecessary repairs as you perform theseInformation section of each manual. maintenance procedures.
34. 34. MAINTENANCE AND LUBRICATION 0B7RECOMMENDED FLUIDS, LUBRICANTS AND FUELSIn order to obtain maximum performance and longest service life from your ISUZU vehicles, it is veryimportant to select and use correctly best lubricants and diesel fuels.When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below,according to the maintenance schedule for each vehicle model.The lubrication intervals in the maintenance schedule and the coverage and period of new vehicle warrantyare based on the use of ISUZU genuine lubricants or recommended lubricants as given in the chart whichwill serve as a guide for selecting lubricants of proper brand name.GRADELUBRICATION MAKE BRAND / TYPEAPI ACEA ISUZU GENUINE BESCO MULTI Z TYPE CE (10W-30)CE ISUZU GENUINE BESCO MULTI Z (10W-30)CD ISUZU GENUINE BESCO MULTI Z SUV (5W-30) CD ISUZU GENUINE BESCO S 3 (10W, 20W, 30, 40)CD Diesel engine crankcase EXXON / ESSOESSOLUBE XD-3+ (15W-40)CG4/CFE2/B2 EXXON / ESSOESSOLUBE XT331 (15W-40)CG-4/CF E2/B2 MOBIL DELVAC HP (15W-40, 20, 30, 40)CF/CE CALTEX / CHEVRONDELO CXJ (15W-40, 30, 40) CF SHELL RIMURA D (15W-40, 30, 40CD/CF ELF PERFORMANCE TROPHY (15W-40) CEE3 TOTAL RUBIA XT (15W-40)CF-4 E2 ISUZU GENUINE BESCO RACING ACE (7.5W-30) SG ISUZU GENUINE BESCO MULTI ACE (7.5W-30)SF ISUZU GENUINE BESCO ACE (10W-30) SE EXXON / ESSOESSO SUPERFLO (15W-40, 15W-50, 20W-50) SJ A2 Gasoline engine EXXON / ESSOESSO UNIFLO (15W-40, 15W-50, 20W-50) SJ A2 crankcase MOBIL MOBIL SUPER XHP (15W-40, 15W-50, 20W-50) SJ A3 CALTEX / TEXACO HAVOLINE FORMULA-3 (15W-40, 20W-50)SJ SHELL HELIX SUPER (10W-30) SJ ELF SUPER SPORTI S (15W-40)SG TOTAL QUARTZ 5000 (15W-40, 20W-50) SJ A2 ISUZU GENUINE BESCO GEAR OIL TRANSAXLE (5W-30) SG EXXON / ESSOESSOLUBE XD-3+ (15W-40)CG-4/CF E2/B2 EXXON / ESSOESSOLUBE XT331 (15W-40)CG-4/CF E2/B2 Manual transmission MOBIL MOBIL SUPER (10W-30) SH Transfer case CALTEX / TEXACO HAVOLINE FORMULA-3 (15W-40, 20W-50)SH SHELL RIMURA D (15W-40) CD/CF ELF SUPER SPORTI S (15W-40) SG/CD TOTAL QUARTZ 5000 (15W-40, 20W-50)SJ/CFA2/B2 ISUZU GENUINE BESCO GEAR OIL SH (80W-90, 90, 140) GL-5 ISUZU GENUINE BESCO SHIFT ON THE FLY (75W-90) GL-5 EXXON / ESSOGEAR OIL GX (85W-90)GL-5 Differential MOBIL MOBILUBE HD (80W-90, 85W-140) GL-5 Shift on the fly system CALTEXTHURBAN GL-5 EP (80W-90, 85W-140) GL-5 (GL-5 only) SHELL SPIRAX HD (90, 140) GL-5 ELF TRANSELF TYPE B (80W-90, 85W-140) GL-5 TOTAL TRANSMISSION TM (80W-90, 85W-140) GL-5 ISUZU GENUINE BESCO GEAR OIL LSD (140)GL-5 EXXON / ESSOGEAR OIL LSA (90) GL-5 DifferentialMOBIL MOBILUBE HD LS (80W-90) GL-5 (Limited Slip Differential) CALTEXGEAR OIL LSD (90) GL-5 ELF TRANSELF TYPE BLS (90)GL-5 TOTAL TRANSMISSION DA (85W-90)GL-5
35. 35. 0B8 MAINTENANCE AND LUBRICATION GRADE LUBRICATION MAKE BRAND / TYPE API ACEAISUZU GENUINE BESCO ATF II, ATF IIIEXXON / ESSOESSO ATF D (DEXRON II-D)Automatic transmissionMOBIL MOBIL ATF (DEXRON III)Power steeringCALTEXATF HD (DEXRON II)SHELL SHELL DONAX TA (DEXRON II-D)ELF ELFMATIC G3 (DEXRON III)TOTAL TOTAL FLUID IID (DEXRON II-D)ISUZU GENUINE BESCO L-2 GREASE (No.2), L-3 GREASE (No.3)Propeller shaft sliding EXXON / ESSORONEX MP (No.2)yoke, Universal joint MOBIL MOBILGREASE HP 222 (No.2)Grease fittingCALTEX / TEXACO STARPLEX-2 (No.2)(General purpose grease)SHELL SHELL RETINAX A (No.2)TOTAL MULTIS EP2, EP3 (No.2, No.3)Propeller shaft sliding ISUZU GENUINE ONE LUBER MO GREASEyokeEXXON / ESSOBEACON Q2 (No.2)Universal joint EXXON / ESSOMULTIPURPOSE GREASE (Moly) (No.2) General purpose grease CALTEXMOLYTEX GREASE EP2 (No.2)(in Molybdenum) TOTAL TOTAL MULTIS MS2 (No.2)ISUZU GENUINE BESCO LLC SUPER TYPE ETEXACO / CALTEX HAVOLINE EXTENDED LIFE ANTIFREEZEEngine cooling systemCOOLANTHAVOLINE XLCEXTENDED LIFE COOLANT 6280 FLUIDTYPEClutch and brake fluid reservoirBesco brake fluid (For light duty)Hydraulic brake fluid SAE J1703FMVSS 116 DOT.3 gradeNOTE:When the recommended lubricants are specified in the workshop manual, follow them.
36. 36. MAINTENANCE AND LUBRICATION 0B9 DIESEL FUEL/APPLICABLE STANDARDJIS (JAPANESE INDUSTRIAL STANDARD)Based on K2204 GAS OILDIN (DEUTSCHE INDUSTRIE NORMEN) Based on EN590 : 1997SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) Based on SAE J-313CBS (BRITISH STANDARD) Based on BS EN590 : 1997NOTE:Use the applicable standard or equivalent for diesel fuels.
37. 37. 0B10 MAINTENANCE AND LUBRICATIONOIL VISCOSITY CHARTLubricants should be carefully selected according to the lubrication chart. It is also important to selectviscosity of lubricants according to the ambient temperature by referring to the following table. OIL VISCOSITY CHART FOR GASOLINE ENGINE APPLY GASOLINE ENGINE OILVISCOSITY GRADE - AMBIENT TEMPERATURE(Single grade) SAE 30SAE 20,20WSAE 10W 25C15C0C 15C38C 13F5F 32F 60F100F(Multi grade) SAE 5W-30 SAE 10W-30 SAE 15W-40,20W-40,20W-50EG-01OIL VISCOSITY CHART FOR DIESEL ENGINEAPPLY DIESEL ENGINE OILVISCOSITY GRADE - AMBIENT TEMPERATURE (Multi grade) SAE 5W-30SAE 10W-30 25C 15C10C 0C15C 25C 30C 13F 5F 14F 32F 60F 77F 86F 905RW017
38. 38. MAINTENANCE AND LUBRICATION 0B11OIL VISCOSITY CHART FOR MANUAL TRANSMISSION AND TRANSFER CASE APPLY ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE(Single grade) SAE 40,50SAE 30 25C10C 5C 10C20C35C 13F 14F41F 50F68F95F(Multi-grade) SAE 5W-30 SAE 10W-30 SAE 15W-40,20W-40,20W-50 ET-12OIL VISCOSITY CHART FOR FRONT AXLE (Manual and Auto locking hub model)AND REAR AXLE APPLY GEAR OILGEAR OIL VISCOSITY GRADE - AMBIENT TEMPERATURE(Single grade)SAE 140SAE 90SAE 80W SAE 75W 25C10C0C 15C30C 35C 13F 14F 32F 59F86F 95F(Multi grade) SAE 75W-90 SAE 80W-90 SAE 80W-140 GA-06
39. 39. 0B12 MAINTENANCE AND LUBRICATION OIL VISCOSITY CHART FOR FRONT AXLE (Shift on the fly model) APPLY GEAR OILGEAR OIL VISCOSITY GRADE AMBIENT TEMPERATURE(Multi grade)SAE 75W 90 SAE 80W 90, 80W 140 25C10C 0C15C30C 35C 13F 14F32F 59F 86F 95F
40. 40. SECTION SERVICE INFORMATION 00 1SECTION 00SERVICE INFORMATION CONTENTS PAGETroubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 3Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0045Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052
41. 41. 00 2 SERVICE INFORMATIONMEMO
42. 42. SERVICE INFORMATION 00 3TROUBLESHOOTINGCONTENTSPAGECircuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 4Heating Cycle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016Fan Control Knob (Fan Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017Blower Motor Does Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018Blower Motor Does Not Run In Certain Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019Blower Motor Does Not Stop at OFF Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019Ceramic Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020Ceramic Heater Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021Ceramic Heater Does Not Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022Air Conditioning Cycle Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023Checking Refrigerant System with Manifold Gauge. . . . . . . . . . . . . . . . . . . . . . . . . 0024Magnetic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00276VD1/6VE1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00274JG2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00314JX1 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037Condenser Fan Does Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038Condenser Fan Does Not Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040Individual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041